Method for use in baking articles of manufacture and mold for use in said method

ABSTRACT

The present invention relates to a method for producing baked goods and a mold apparatus having a cavity in a desired shape for use in said method, the mold apparatus comprising a gap that allows for venting of vapor produced during heating or baking of a mixture in the mold apparatus but does not allow any significant amount of the mixture to escape from the cavity of the mold apparatus via the gaps.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.12/340,373, filed Dec. 19, 2008, which is a continuation of U.S. patentapplication Ser. No. 10/608,441, filed Jun. 27, 2003, which isincorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention generally relates to methods for the production of bakedgoods and articles of manufacture and molds for use in said methods.

2. Background

The majority of the molding systems producing baked goods today comprisea two piece mold with a female lower half and a male upper half. In somecases, the female lower half is made up of two halves—for example, afemale ice cream cone mold is usually made up of two halves as can beseen U.S. Pat. No. 5,693,355 to Haas. Typically, the molds are heatedand remain heated to a temperature that is sufficient to bake thematerial deposited in the molds within a certain time period withoutburning the material.

As the product is baked, water or other liquid in the mixture is turnedinto steam or other vapor that must be discharged from the mold to allowfor proper formation of the final product. This is typicallyaccomplished through vents in the mold apparatus. As an unintendedresult of having vents for vapor or steam to escape, excess material isalso typically ejected from the cavity of the mold via the vent. Theventing of excess material causes significant waste of both rawmaterials and energy. Loss of raw materials, a significant cost in themanufacturing process, can be in excess of 20% to 30%. Similarly, tocompensate for the loss of material, additional material must be addedto the mold which requires additional energy for baking, also asignificant expense in most processes.

Further, additional steps must also be added to the manufacturingprocess for removal of the excess material from the baked product toproduce the final product. The vents are usually trimmed and/or sandedand then disposed of along with the excess material. Moreover, thetrimming process itself can cause defects and thus increase theprobability of rejection of the final product. Finally, if vent wearoccurs, the entire mold may have to be replaced or additional materialadded to the mold because vent cross-section is an important componentin controlling how much material is vented out of the mold apparatus.

Accordingly, there is a need in the art for improved molds and methodsfor use of said molds for the manufacture of baked goods that allow forventing of vapor produced during heating or baking without substantialloss of material.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a method formanufacturing articles or baked goods that allows for venting of vaporproduced during heating or baking without substantial loss of material.

It is another object of the present invention to provide a mold having agap or gaps for venting vapor produced during heating or baking withoutsubstantial loss of material.

These and other aspects of the present invention which may becomeobvious to those skilled in the art through the following description ofthe invention are achieved by a method for baking articles ofmanufacture and a mold for use in said method.

One embodiment of the present invention is a method comprising the stepsof adding a mixture to a mold apparatus having a cavity and baking themixture in the mold apparatus until the mixture is form stable, whereinupon contact of the mixture with the surface of the cavity, a skin isformed on the exterior of the mixture, and wherein the mold apparatuscomprises a gap such that vapor can exit the cavity of the moldapparatus through the gap without substantial loss of the mixturethrough the gap.

Another embodiment of the present invention is a mold apparatuscomprising a cavity, a gap in communication with the cavity and theexterior of the mold apparatus for venting vapor wherein the gap isconfigured such that it allows escape of vapor from the cavity while atthe same time does not allow escape of a mixture from the cavity.

A third embodiment of the present invention is a mold apparatuscomprising a male mold half, a female mold half wherein contact of themale mold half and the female mold half forms a cavity in a desiredshape, and a gap in communication with the cavity and the exterior ofthe mold apparatus for venting vapor wherein the gap is configured suchthat it allows escape of vapor from the cavity while at the same timedoes not allow escape of a mixture from the cavity.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is cross-sectional of an open two-piece mold.

FIG. 2 is cross-sectional of a closed two-piece mold.

FIG. 3 shows a vent in a mold.

FIG. 4 is a perspective view of a venting feature applied in ahorizontal fashion to a female mold.

FIG. 5 is a cross-section view of a venting feature applied in ahorizontal fashion to a female mold.

FIG. 6 is a perspective exploded view of a venting feature applied in ahorizontal fashion to a female mold.

FIG. 7 is a perspective view of a venting feature applied in a verticalfashion to a female mold.

FIG. 8 is a cross-section view of a venting feature applied in avertical fashion to a female mold.

FIG. 9 is a perspective exploded view of a venting feature applied in avertical fashion to a female mold.

FIG. 10 is a perspective view of a venting feature applied in ahorizontal fashion to a male mold.

FIG. 11 is a cross-section view of a venting feature applied in ahorizontal fashion to a male mold.

FIG. 12 is a perspective exploded view of a venting feature applied in ahorizontal fashion to a male mold.

FIG. 13 is a perspective view of a venting feature applied in a verticalfashion to a male mold.

FIG. 14 is a cross-section view of a venting feature applied in avertical fashion to a male mold.

FIG. 15 is a perspective exploded view of a venting feature applied in avertical fashion to a male mold.

DETAILED DESCRIPTION OF THE INVENTION

In order to fully understand the manner in which the above-reciteddetails and other advantages and objects according to the invention areobtained, a more detailed description of the invention will be renderedby reference to specific embodiments thereof.

1. Molding Method

A method according to the present invention comprises the steps ofproviding a mold apparatus having a cavity in the shape of a desiredfinal product and a gap or gaps for venting vapor from the moldapparatus produced during heating or baking, heating or baking the moldapparatus, adding a mixture that is liquid or semi-liquid to the cavityof the mold apparatus prior to closing the mold apparatus and closingthe mold apparatus, wherein as vapor or steam is produced in the cavityduring heating or baking, the mixture is pushed by vapor or steampressure to completely fill the cavity, and upon sufficient contact ofthe mixture to the heated mold apparatus a skin forms on the outersurface of the mixture, the skin being permeable or semi-permeable tothe vapor or steam and the skin and gap being such that, in combination,they allow escape of steam or vapor from the cavity to the exterior ofthe mold apparatus but do not allow any significant amount of themixture to escape. Any significant amount of mixture as referred toherein is any amount the loss of which would cause any one of theaforementioned drawbacks found in the prior art in a meaningful amount,such as waste of raw materials, waste of energy needed to heatadditional mixture, additional processes to remove excess material toform the final product and clogging of the gap or gaps

The vapor escapes while the mixture is retained in the cavity becausethe gap is of sufficient size—i.e., small enough—that the skin formed onthe surface of the mixture from contact of the mixture with the heatedmold surface, when under sufficient pressure from the steam or vaporproduced during heating or baking of the mixture, allows the steam orvapor to escape through the skin and then through the gap to theexterior of the mold apparatus without rupture of the skin. Because theskin is not permeable to the mixture, which may still be liquid orsemi-liquid prior to the completion of heating or baking, the mixturecannot escape from the cavity of the mold apparatus.

The aforementioned method according to the present invention allows forventing of the vapors produced during baking without significant loss ofmixture and the associated drawbacks of said loss outlined above such aswaste of raw materials, waste of energy needed to heat additionalmixture, additional processes to remove excess material to form thefinal product and clogging of the gap or gaps.

The aforementioned method according to the present invention may be usedto manufacture both edible baked goods and other baked products such asstarch-based materials for use as food containers and the like. Mixturesfor use in said method are typically water-based. One skilled in theart, however, will recognize that the mixtures need not be water-based,such as alcohol-based mixtures or other non-water-based mixtures.Specific examples of mixtures that may be used said method should bereadily apparent to one skilled in the art and include, but are notlimited to, common baking mixtures such as waffle, cookie dough, or icecream cone batter, starch-based mixtures comprised of starch and waterand mixtures comprising composite materials mixed with resins that formskins which are still permeable to the gases produced during heating orbaking. Further, specific baking procedures such as heating temperatureand time will vary depending upon the specific mixture to be heated orbaked and should be apparent to one skilled in the art.

2. Mold Apparatus

Referring to FIGS. 1 and 2, a mold 5 according to the present inventionis shown having a male mold half 10 and a female mold half 15 to form acavity 20. The mold 5 can have a variety of shapes depending upon thedesired shape of the final product to be baked. The mold 5 that is shownis configured such that the cavity 20 is in the shape of a bowl.

The male mold half 10 and the female mold half 15 may be held togetherby means commonly known in the art such as a hydraulic press, mechanicallocking mechanism or clamping mechanism, not shown. As described above,the complete filling of the cavity 20 with a mixture that is initiallyliquid or semi-liquid is caused by the force created during heating orbaking by the formation of vapor in the cavity 20. The vapor pressurethen pushes the mixture to substantially fill the cavity 20.Accordingly, it is not necessary to press the male and female moldhalves 10 and 15 together to push the material to fill the cavity 20 solong as the male and female mold halves 10 and 15 are held in positionduring heating or baking. Both mechanical pressing and vapor pressure,however, could be used in combination to fill the cavity 20 if sodesired.

Referring to FIG. 3, a section of the mold 5 is shown having a gap 25for venting steam or other vapor formed during heating or baking fromthe cavity 20 to the exterior of the mold 5. The gap 25 having a firstportion 30 in communication with the cavity 20 and a second portion 35in communication with the first portion 30 and the exterior of the mold5 wherein the second portion 35 is wider than the first portion 30. Thegap 25 is configured such that, in combination with the skin formedduring heating or baking as described above, the gap 25 allows forventing steam or other vapor formed during heating or baking withoutallowing the escape of the mixture. The dimensions of the gap 25 willvary depending on the particular mixture used. Generally, it has beenfound that the first portion 30 of the gap 25 has width preferably ofabout 0.001 inches to about 0.030 inches, and more preferably about0.001 inches to about 0.015, and most preferably about 0.001 inches toabout 0.006 inches, and has a length preferably of about 0.001 inches toabout 2 inches, and more preferably about 0.001 to about 0.5 inches, andmost preferably about 0.001 to about 0.1 inches. Further, the firstportion 30 or the second portion 35 of the gap 25 may vary or beconstant along its respective length.

Material used to form the mold 5 can be selected from common materialsknown in the art including, but not limited to, metals such as cast ironand aluminum or other suitable materials. Further, depending on thespecific material to be selected and the specific mixture to be formedby the aforementioned method, the surfaces of the cavity 20 of the mold5 may be treated with methods such as sand blasting, plating with metalssuch as nickel plating or other treatment methods commonly known in theart where said surface treatment may aide in the formation of desiredcharacteristics in the surface of the final product or improve theproduction process such as facilitating the removal of the product fromthe cavity 20 of the mold 5 after formation. Further, a heatingmechanism may be incorporated into the mold 5.

In addition, referring to FIG. 2, during molding the mold 5 may be heldslightly open leaving a space at 37 at the outermost interface betweenthe male mold half 10 and the female mold half 15 that extends aroundthe circumference of the outermost interface such that vapor mayinitially escape through said space at 37. As the heating or bakingprocess proceeds, the mold 40 is substantially closed sealing the spaceat 37. This substantial closing of the mold 40 will insure that the malemold half 10 and the female mold half 15 are substantially aligned priorto the product becoming form stable and will also allow for some heattransfer between the male mold half 10 and the female mold half 15 toreduce temperature differentials between the male mold half 10 and thefemale mold half 15.

a. Venting Configurations

Referring to FIGS. 4 to 6, a mold 40 according to the present inventionis shown having a female mold half 45 and a male mold half 50 withhorizontal venting of the female mold half 45. Referring to FIG. 4, thefemale mold half 45 is shown having a gap 55 for venting gas formedduring heating or baking. Referring to FIG. 6, the female mold half 45is further comprised of a lower half 60 and an upper half 65 heldtogether by fasteners 90 such as bolts or screws.

Referring to FIG. 5, a cross-section along the plane A-A of FIG. 4 isshown where the gap 55 is visible on opposite sides of the female moldhalf 45, the gap 55 having a channels 85, a first portion 70 and asecond portion 75, where the second portion 75 is wider than the firstportion 70. Section B of FIG. 5 enlarges a portion of mold 40 showing acavity 80 and the first portion 70, the second portion 75 and thechannels 85 of gap 55.

Referring to FIG. 6, an exploded view of the mold 40 is shown having thegap 55 in the female mold half 45 wherein the female mold half 45 havingan upper half 65 and lower half 60 wherein the lower half 60 of thefemale mold half 45 has channels 85 which when the lower half 60 and theupper half 65 of the female mold half 45 are assembled and held togetherby fasteners 90, form the gap 55 as shown in FIGS. 4 and 5. Further,when assembled, the first portion 70 and the second portion 75 of thegap 55 are in communication with the entire circumference of the moldcavity 80 where the upper half 65 and the lower half 60 of the femalemold half 45 meet, and further being in communication with the channels85 which are in turn in communication with the exterior of the mold 40.

Referring to FIGS. 7 to 9, a mold 100 according to the present inventionis shown having a male mold half 105 and a female mold half 110 havingvertical venting in the female mold half 110. The female mold half 110further comprising a first half 115 and a second half 120 held togetherby fasteners 125 and having a gap 130 for venting steam or vapor duringheating or baking, the gap 130 being formed by grooves in at least oneof the first half 115 or the second half 120 of the female mold half110.

Referring to FIG. 8, a cross section along the plane C-C of FIG. 7 isshown wherein the gap 130 is visible in the female mold half 110.Section D of FIG. 8 enlarges a portion of the mold 100 showing thecavity 135 and the first portion 140 and the second portion 145 of gap130, wherein the second portion 145 is wider than the first portion 140and wherein the cavity 135 is in communication with the first portion140 of the gap 130 which in turn is communication with the secondportion 145 of the gap 130 which in turn is communication with theexterior of the female mold half 110.

Referring to FIG. 9 an exploded view of the mold 100 is shown whereinthe first half 115 and the second half 120 of the female mold half 110,held together by fasteners 125, when assembled form the first portion140 and second portion 145 of the gap 130 by contact of the first half115 and the second half 120 of the female mold half 110 and wherein thefirst portion 140 and the second portion 145 of the gap 130 extend alongthe entire length of the cavity 135 where the first half 115 and thesecond half 120 of the female mold half 110 meet.

Referring to FIGS. 10 to 12, a mold 160 according to the presentinvention is shown having a male mold half 165 and a female mold half170 and having horizontal venting in the male mold half 165. The malemold half 165 having a gaps 175 for venting steam or vapor duringheating or baking.

Referring to FIG. 11, a cross section along the plane E-E of FIG. 10 isshown wherein the venting gap 175 is visible in the male mold half 165.Section F of FIG. 11 enlarges a portion of mold 160 showing a moldingcavity 180 and a first portion 185, a second portion 190 and a channel95 of gap 175, wherein the second portion 190 is wider than the firstportion 185. Further, the mold cavity 180 is in communication with thefirst portion 185 of the gap 175 which in turn is communication with thesecond portion 190 of the gap 175 which in turn is communication thechannel 195 of the gap 175 which in turn is in communication with theexterior of the male mold half 165.

Referring to FIG. 12 an exploded view of the mold 160 is shown whereinthe male mold half 165 is further comprised of a first half 205 and asecond half 210 held together by fasteners 200 wherein, when assembled,the first portion 185 and second portion 190 of the gap 175 is formed bycontact of the first half 205 and the second half 210 of the male moldhalf 165 and wherein the first portion 185 and the second portion 190 ofthe gap 175 extend along the entire circumference of the cavity 180where the first half 205 and the second half 210 of the male mold half165 meet.

Referring to FIGS. 13 to 15, a mold 250 according to the presentinvention is shown having a male mold half 255 and a female mold half260 having vertical venting in the male mold half 255. The male moldhalf 255 further comprising a first half 265 and a second half 270 heldtogether by fasteners 295, and gaps 275 for venting steam or vaporduring heating or baking.

Referring to FIG. 14, a cross-section along the plane G-G of FIG. 12 isshown wherein the gap 275 is visible in the male mold half 255. SectionH of FIG. 13 enlarges a portion of the mold 250 showing the cavity 280and the first portion 285 and the second portion 290 of gap 275, whereinthe second portion 290 is substantially wider than the first portion 285and wherein the second portion 290 extends to the exterior of the malemold half 255 to vent steam or other vapor produced during heating orbaking.

Referring to FIG. 15, an exploded view of the mold 250 is shown wherein,when assembled, the cavity 280 is in communication with the firstportion 285 of the gap 275 which in turn is communication with thesecond portion 290 of the gap 275 which in turn is communication withthe exterior of the male mold half 255 at 300. The first half 265 andthe second half 270 of the male mold half 255, held together byfasteners 295, when assembled form the first portion 285 and secondportion 290 of the gap 275 by contact of the first half 265 and thesecond half 270 of the male mold half 255 and wherein the first portion285 and the second portion 290 of the gap 275 extend along the entirelength of the cavity 280 where the first half 265 and the second half270 of the male mold half 255 meet.

Although the invention has been described with respect to specificembodiments and examples, it will be readily appreciated by thoseskilled in the art that modifications and adaptations of the inventionare possible without deviation from the spirit and scope of theinvention. Accordingly, the scope of the present invention is limitedonly by the following claims.

1-40. (canceled)
 41. A method comprising: adding a mixture to a moldapparatus having a cavity; and baking the mixture in the mold apparatusuntil the mixture is form stable; wherein upon contact of the mixturewith the surface of the cavity, a skin is formed on the outer surface ofthe mixture; and wherein the mold apparatus comprises: a cavity having acavity inner surface; and a gap in communication with the cavity and theexterior of the mold apparatus for venting vapor or steam, wherein: thegap comprises a first portion which extends in a substantiallycontinuous manner along the cavity inner surface, wherein the firstportion has a width that is in a range from about 0.001 inches to about0.030 inches and a length that is substantially greater than said width;the gap further comprises a second portion in communication with thefirst portion wherein the second portion is wider than the firstportion; and the gap is configured such that vapor or steam is ventedfrom the cavity without escape of a significant amount of the mixturefrom the cavity and without substantial clogging of the gap withmaterial from the vapor or steam.
 42. The method of claim 1 furthercomprising the step of heating the mold apparatus prior to addition ofthe mixture.
 43. The method of claim 1 wherein when the mixture is addedto the mold apparatus the formation of vapor and steam causes themixture to substantially fill the cavity.
 44. The method of claim 1wherein the first portion of the gap has a width that is in a range fromabout 0.001 inches to about 0.015 inches.
 45. The method of claim 1wherein the first portion of the gap has a length that is in a rangefrom about 0.001 inches to about 2 inches.
 46. The method of claim 1wherein the first portion of the mold apparatus extends in asubstantially continuous manner along at least 10 percent of a perimeterof the cavity inner surface.
 47. The method of claim 1 wherein the firstportion extends in a substantially continuous manner along at least 50percent of a perimeter of the cavity inner surface.
 48. The method ofclaim 1 wherein the first portion extends in a substantially continuousmanner along a perimeter of the cavity inner surface.
 49. The method ofclaim 1 wherein the gap spans a distance extending from the cavity tothe exterior of the mold apparatus.
 50. A method comprising: adding amixture to a mold apparatus having a cavity; and baking the mixture inthe mold apparatus until the mixture is form stable; wherein uponcontact of the mixture with the surface of the cavity, a skin is formedon the outer surface of the mixture; and wherein the mold apparatuscomprises: a male mold half; a female mold half wherein contact of themale mold half and the female mold half forms a cavity having an innercavity surface in a desired shape; and a gap in communication with thecavity and the exterior of the mold apparatus for venting vapor orsteam, wherein: the gap comprises a first portion which extends in asubstantially continuous manner along the cavity inner surface, whereinthe first portion has a width that is in a range from about 0.001 inchesto about 0.030 inches and a length that is substantially greater thansaid width; the gap further comprises a second portion in communicationwith the first portion wherein the second portion is wider than thefirst portion; and the gap is configured such that vapor or steam isvented from the cavity without escape of a significant amount of themixture from the cavity and without substantial clogging of the gap withmaterial from the vapor or steam.
 51. The method of claim 10 whereinwhen the mixture is added to the mold apparatus the formation of vaporand steam causes the mixture to substantially fill the cavity.
 52. Themold apparatus of claim 10 wherein the female mold or the male moldfurther comprises a first half and a second half held together by aremovable fastener, and the gap.
 53. The method of claim 10 wherein thefirst portion is in communication with the cavity and the second portionis in communication with the first portion and the exterior of the moldapparatus.
 54. The method of claim 13 wherein the gap is along thehorizontal axis of the mold apparatus.
 55. The method of claim 14wherein the first portion of the gap has a width in a range from about0.001 inches to about 0.015 inches.
 56. The method of claim 15 whereinthe first portion of the gap has a depth in a range from about 0.001inches to about 2 inches.
 57. The method of claim 13 wherein the secondportion of the gap is in communication with a channel which is incommunication with the exterior of the mold apparatus.
 58. The method ofclaim 17 wherein the gap is formed by grooves in at least one of thefirst half or second half when the first half and the second half are incontact.
 59. The method of claim 13 wherein the gap is along thevertical axis of the mold apparatus.
 60. The method of claim 19 whereinthe first portion of the gap has a width in a range from about 0.001inches to about 0.015 inches.
 61. The method of claim 20 wherein thefirst portion of the gap has a depth in a range from about 0.001 inchesto about 2 inches.
 62. The method of claim 19 wherein the gap is formedby grooves in at least one of the first half or second half when thefirst half and the second half are in contact.
 63. The method of claim10 wherein the gap is formed only in the male mold half.
 64. The methodof claim 10 wherein the gap is formed only in the female mold half. 65.The method of claim 10 wherein the only communication between the cavityand exterior of the mold is through the gap.
 66. The method of claim 10wherein the gap is formed between said male and female mold halves uponcontact of said halves and the first portion of the gap extends in asubstantially continuous manner along the perimeter of the cavity innersurface.